Adjustable Support Rails for Tile Installation on Uneven Surfaces

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Solution Overview

Problem

Installing tile on non-horizontal surfaces, especially vertical surfaces, is time-consuming and prone to material loss due to breakage, and existing methods struggle with uneven surfaces.

Innovation Solution

The system comprises support rails and mounting anchors that provide a secure and adjustable framework for tile installation, allowing for level and plumb foundation on uneven surfaces, with corner and edge anchors that separate tiles and apply compression for secure adherence.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional tile installation methods are used on non-horizontal surfaces, then the installation process is simple, but it is time-consuming and results in high material loss due to breakage

Engineering Contradiction:

Improveinstallation speedVSAvoidtile breakage

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The support rails are pre-installed and secured to the surface before tile placement, creating a stable framework that prevents tile breakage during installation. This preliminary preparation eliminates the need for complex temporary support structures and reduces installation time while preventing tile breakage.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support rails act as an intermediary structure between the installation surface and the tiles, providing a stable platform that distributes loads and prevents direct contact between tiles and uneven surfaces, thereby reducing breakage and improving installation efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If flat tile products are installed on non-perfectly-flat surfaces, then the installation process is straightforward, but the tiles become difficult to install securely

Engineering Contradiction:

Improveinstallation easeVSAvoidadherence security

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The support rails are divided into multiple adjustable segments that can be independently positioned and secured at different locations along the surface. This segmentation allows the system to adapt to uneven surfaces while maintaining a flat, stable platform for tile installation, improving both ease of installation and adherence security.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support rails incorporate adjustable mounting mechanisms that allow dynamic positioning and securing at various angles and heights, enabling the system to accommodate uneven surfaces while providing a stable, level platform for tile installation.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If corner anchors are used to separate tiles by a predetermined distance, then tile spacing is precise, but the anchor structure becomes more complex

Engineering Contradiction:

Improvetile spacing precisionVSAvoidanchor structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The corner anchor combines multiple functions into a single integrated component: it provides precise spacing, secures the tile to the support rail, and maintains the predetermined distance from adjacent tiles. This merging of functions reduces the number of separate components needed and simplifies the overall structure while maintaining precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The corner anchor serves multiple purposes simultaneously: it acts as a spacing element, a securing mechanism, and a positioning tool. This multi-functionality reduces device complexity by eliminating the need for separate components for each function, while still achieving precise tile spacing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enhances the efficiency and security of tile installation on non-horizontal surfaces by reducing material loss and improving adherence, allowing for easier installation on uneven surfaces.

Implementation Method 1

adhering the tile to surfaces of the first and second support rail and in contact with the edge anchor (e.g., using an adhesive disposed between the tile and the first and/or second support rail)

Methodology Applied

Scientific EffectAdhesion: Adhesive